Jump to content

  • Join Today, It's Simple and FREE!

    As a member, you can post in our forums, upload your photos and videos, use and contribute to our downloads, create your own member page, add your ATV events, and even start your own ATV club to host your own club forum and gallery.  Registration is fast and you can even login with social network accounts to sync your profiles and content.


2004 Arctic Cat 500 - Carb & Fuel Filter Questions

Recommended Posts

I am going to help a buddy with his 2004 Arctic Cat 500 TBX next week. I don't own a ATV, but am a pretty good mechanic and have been working on my own dirt bikes, road bikes, cars, trucks and small engine equipment (mowers, tractors, leaf blowers, chain saws, etc.) my whole life. I haven't brought anything to a shop for anything but tires in about 20 years. I am very confident I can do the job.

The problem is, when at idle, gas flows out of the overflow at the bottom of the carb. From my research on the internet, I know the cause is probably either;

1. (less likely) mis-adjusted float height (should be adjusted to 17mm). or

2. (more likely) debris between the needle valve and the seat.

My plan is to remove the carb, dissassemble, check the float height and give it a thorough cleaning.

My problem is my buddy lives 100 miles from me and is just going to trailer the quad to my house the day I'm going to work on it and wait while I fix it. So, I'm not going to get a chance to examine the quad before I dig in. I know, from my research that the '04 500 TBX does not have a fuel filter and it is a good idea to have one. Problem is, without being able to look at the quad ahead of time, I have no idea what size the fuel line is. The closest parts store is quite a distance from me, so I'd like to have all of the parts before he arrives.

My specific questions are:

1. When disassembling and reassembling the '04 500 TBX carb, do I need any new gaskets or O-rings or can I re-use what is on there?

2. Since the '04 500 TBX does not come with a fuel filter, could someone please give me a SPECIFIC RECOMMENDATION (i.e., Fram F5432, Purolator Z657, etc.) of a fuel filter that I can simply splice in the middle of the existing fuel line?

Keep in mind, I am asking these questions because I will not actually get to see the quad until it is time to work on it.

Any help would be appreciated.



Share this post

Link to post
Share on other sites

Does anyone have an '04 500 TBX that they can pull a fuel line before the carb off quickly any measure the inside diameter? Getting that dimension will allow me to buy a fuel filter before my buddy brings the ATV to my house next week.

Let me know.



Share this post

Link to post
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

  • Similar Topics

    • By Ajmboy
      View File 2018 Textron Off Road Alterra 500 Service Manual
      2018 Textron Off Road Alterra 500 Service Manual
      Submitter Ajmboy Submitted 12/16/2018 Category Textron Off Road ATV  
    • By Ajmboy
      Unfortunately I didn't notice some of the rust hitting the undercarriage of my 2004 Yamaha Grizzly 660, but saw it the other day when I was doing some maintenance, oil change, air filter, spark plug, etc. The left side footrest broke and that's causing the plastic to hit the front wheel. It broke right at the welds from too much rust. Looks to me like what I need is (looked this up on yamahapartshouse.com):
      YAMAHA FOOTREST BOARD 5KM-27481-10 Left side (broken)
      YAMAHA FOOTREST BOARD 5KM-27488-10-00 Right side (rusted and will probably break eventually)

      Does anyone have a less expensive source? I did see on ebay a couple of listings but it still comes out to @ $50 each, 
    • By Juan Gutierrez
      hello all. i have a suzuki lt230e engine. hopefully i can get it to drive some wheels soon.
    • By My kiwi shed
      Hi there everyone. Just seeing if there is advice on a problem I have before I start digging too deep. 
      I recently bought this creally nice 2004 King quad ltf300 with only 2400km..
      Everything things works great except when engaged into 4wd or diff lock it has a clicking noise ( sounds like broken teeth etc) are the front diffs known to blow?  Or the transfer from engine?
      I am yet to test on some loose ground to see if I'm getting drive at front .
      I will be driving in to find problem in next few weeks but thought I'd see if anyone might know what it is first. Cheers

    • By Chris Stokes
      What is a good option for a 13 year old that is dying to get her very own atv to ride? Thanks in advance for your recommendations. I currently own a Polaris Sportsman 570 and have been happy with the Polaris sportsman line but have ruled out other brands.
  • Similar Tagged Content

    • By Trenton
      Hello. I am a new member as of today. I had a quick question to ask. I recently was driving mt HONDA RANCHER 2004 GPSscape 400 and my display stopped working. I was driving the atv and all of a sudden the speedometer and the service lights went out. Also the lights stopped working. I am still able to shift gears, change from 2wd to 4wd, and can still select if I want EPS or Auto. I have checked my fuse box and have changed a few of them around. It did not change anything. I was wondering if anyone had any idea of what had happend. Thank you for your time- Trenton 
    • Guest
      By Guest
      Ok...I'm gettin' me juevos ready to do an oir filter clean....
      Went to my local harley/quad dealer and he had me purchase the No-Toil kit (Cleaner, Air Filter Oil, Rim Grease)
      What I've read is that the No-Toil cleaner will NOT clean
      other oils off air filters....just the No-Toil oil....
      So, I've also read that others have cleaned their air filters
      in the kitchen sink, used gasoline, or used flash solvent....
      Looking for advice as I've mentioned I'm very mechanically
      I'm going to wash the air box seal in the sink and give it a good dry....
      One more thing......No-Toil or Bel-Ray for filter oil?
    • By LTZ-Zach
      So i was riding the other day and my quad randomly shut off. It started back up and ran completely fine for a little while and then it started idling terribly.
      I cleaned the carb and changed all the jets and everything except the float due to the rebuild kit not coming with one and it actually runs worse then it did before.
      It will run and idle decent now but when I give it gas it dies.
      Does anybody know what could be wrong?
      I also changed the spark plug and air filter along with the oil and oil filter.
    • By gregj49
      Blows out black smoke when you rev it up how do you adjust the carb?
  • Recently Browsing   0 members

    No registered users viewing this page.

  • Create New...